Apparatuses and methods for producing containers

ABSTRACT

The apparatus includes an operating unit, which can be a welding unit for welding a closing film to an edge zone of a containing element or a separating unit for separating containing elements from portions of sheet material. The apparatus includes a control unit programmed to enable the operating unit to selectively process a continuous strip of containing elements or discrete groups of containing elements.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of application Ser. No. 12/920,620 withan effective filing date of Jan. 7, 2011. Application Ser. No.12/920,620 is a § 371 National Stage Entry of PCT InternationalApplication No. PCT/IB2009/000386 filed Mar. 2, 2009. PCT/IB2009/000386claims priority to IT Application No. MO2008A000063 filed Mar. 5, 2008.The entire contents of these applications are incorporated herein byreference.

BACKGROUND OF THE INVENTION

The invention relates to apparatuses and methods for producingcontainers from a thermoformable sheet material. The containers producedwith the apparatuses and the methods according to the invention aresuitable for being filled with liquid or pasty products, which possiblysolidify after being cooled, or with powder or loose products. Suchcontainers, after being filled, can be used in the food, pharmaceutical,cosmetic and similar industries.

In some countries in which low-cost labour is available, it is known topackage products inside containers made of thermoformable material byperforming a large number of operations manually. This packaging methodhas the drawback that, in addition to requiring a very long time forproducing finished containers, may give rise to defects in the finishedcontainers if operators commit imprecisions during manual operations.

In order to overcome these drawbacks, a production line is known forproducing containers comprising a forming unit for obtaining a pluralityof cavities on a sheet material. A filling unit, arranged downstream ofthe forming unit, enables the cavities obtained on the sheet material tobe filled. The production line further includes a welding unit,positioned downstream of the filling unit for thermowelding a closingsheet on the sheet material on which the cavities are obtained, and acutting unit arranged downstream of the welding unit to separate singlecontainers or groups of containers from the sheet.

The known production line, whilst it enables packaging operations to bespeeded up and good-quality containers to be obtained, is notparticularly versatile. Further, such a line is suitable for serialproduction of large quantities of containers, but it is not suitable forproducing small batches of containers that are different from oneanother, as occurs when samples have to be arranged to check whetherconsumers will like a certain type of product.

SUMMARY OF THE INVENTION

An object of the invention is to improve known apparatuses and methodsfor producing containers.

A further object is to provide apparatuses and methods that enable thenumber of manual operations to be reduced that are required forobtaining containers.

Another object is to provide apparatuses for producing containers thatare provided with great versatility.

Still another object is to provide apparatuses that can easily be usedboth for serial production of large quantities of containers and forproduction of small batches.

In a first aspect of the invention, there is provided an apparatuscomprising a welding unit for welding a closing film to an edge zone ofa containing element, wherein the apparatus comprises a control unitprogrammed to enable the welding unit to process selectively acontinuous strip of containing elements or discrete groups of containingelements.

Owing to the first aspect of the invention, it is possible to obtain anapparatus for closing containing elements by means of a closing filmthat can operate both in isolation and integrated into a productionline. In the first case, the apparatus processes discrete groups ofcontaining elements that may have been subjected to manual operations,for example manual filling operations. These discrete groups can be usedwhen small samples of containers have to be arranged or in countries inwhich cheap labour is available. In the second case, the apparatusprocesses a continuous strip of containing elements and enableshigh-speed containers to be obtained.

In a second aspect of the invention, there is provided an apparatuscomprising a separating unit for separating containers from portions ofsheet material, wherein the apparatus comprises a control unitprogrammed to enable the separating unit to process selectively acontinuous strip of containers or discrete groups of containers.

The apparatus according to the second aspect of the invention is veryversatile, inasmuch as it can be inserted into a production line toproduce containers from a sheet material that is unwound in a continuousmanner, but can also work in isolation, i.e. outside the production lineto process discrete groups of previously formed containing elements.

In a third aspect of the invention, there is provided an apparatuscomprising a coupling device for coupling a closing film with a sheetmaterial having a plurality of containing cavities, wherein it comprisesa cutting unit for removing a portion of the closing film so that, whenthe closing film is coupled with the sheet material, a zone of the sheetmaterial remains uncovered by the closing film.

Owing to the cutting unit combined with the coupling device, it ispossible to obtain containers in a particularly rapid and automatedmanner.

In one embodiment, the apparatus comprises a supplying device forsupplying the closing film in a supply direction.

In a further embodiment, the apparatus comprises an adjusting device foradjusting the position of the cutting unit along the supply direction.

In a fourth aspect of the invention, there is provided a methodcomprising removing a portion of a closing film in a cutting unit andcoupling the closing film with a sheet material having a plurality ofcontaining cavities, wherein the method comprises the step of adjustingthe position of the cutting unit so that, after coupling, a preset zoneof the sheet material is positioned at a region of the closing film fromwhich the portion has been removed.

In one embodiment, the preset zone that it is desired to maintainuncovered by the closing film comprises a tab for opening a containerincluding a containing cavity.

In a further embodiment, the preset zone that it is desired to maintainuncovered by the closing film comprises a protrusion that projects froma face of said sheet material opposite a further face of said sheetmaterial from which the containing cavities project.

By adjusting the position of the cutting unit, it is possible to ensurethat a desired zone of the sheet material on which the containingcavities are obtained remains devoid of the closing film, which enableseven special containers to be produced in a highly automated manner,i.e. containers that are different from the common containers in whichthe closing film can be applied in a uniform manner.

In a fifth aspect of the invention, there is provided an apparatuscomprising an unwinding device for unwinding a closing film from a reel,a coupling device for coupling the closing film with a sheet materialhaving a plurality of containing cavities, wherein it comprises ajoining device arranged upstream of the coupling device for joining tothe closing film a removing element that is usable by a consumer toremove contents from a containing cavity.

In a sixth aspect of the invention, there is provided a methodcomprising unwinding a closing film from a reel, coupling the closingfilm with a sheet material having a plurality of containing cavities,wherein, before coupling, the method comprises the step of joining tothe closing film a removing element that is usable for removing contentsfrom a containing cavity.

In one embodiment, the removing element comprises a spoon element.

In one embodiment, the spoon element is substantially flat.

Owing to the fifth and sixth aspect of the invention, it is possible toproduce in a highly automated manner a plurality of containers providedwith a removing element that the consumer can use, for example, foreating a product contained in a container.

In a seventh aspect of the invention, there is provided a methodcomprising the steps of advancing a portion of sheet material from whicha plurality of containers is obtained, separating the containers fromthe sheet material, wherein after separating, each container falls intoa corresponding seat of a collecting tray underneath.

In an eighth aspect of the invention, an apparatus is providedcomprising a separating unit for separating containers from a portion ofsheet material, a conveying device for conveying to the separating unitcollecting trays suitable for receiving the containers, the conveyingdevice comprising a reference device for positioning the collectingtrays in a preset position with respect to the separating unit, so thateach container can be received in a corresponding seat of the collectingtray.

The collecting tray in which the containers are received, after beingfilled, can be removed manually or automatically and be used to supportthe containers during subsequent handling steps, for example duringtransporting of the containers to retailers or also during selling. Thisenables the handling steps of the containers after production to beimproved.

BRIEF DESCRIPTION OF THE FIGURES

The invention can be better understood and implemented with reference tothe attached drawings that illustrate some embodiments thereof by way ofnon-limiting example, in which:

FIG. 1 is a schematic side view showing an apparatus for forming aplurality of containing cavities on a sheet material;

FIG. 2 is a schematic plan view of the apparatus in FIG. 1;

FIG. 3 is a schematic plan view of a group of containing cavities thatare obtainable from the apparatus in FIG. 1;

FIG. 4 is a schematic plan view of an apparatus for applying a closingfilm to a plurality of containing cavities;

FIG. 5 is a schematic side view of a first portion of the apparatus inFIG. 4, taken in the direction A in FIG. 4;

FIG. 6 is a schematic side view of a second portion of the apparatus inFIG. 4, taken from the direction B in FIG. 4;

FIG. 7 is a schematic plan view of a container that is obtainable withthe apparatus in FIG. 4;

FIG. 8 is a schematic section of a packaging unit formed by twocontainers of the type shown in FIG. 7;

FIG. 9 is a schematic section of a container that is obtainable with theapparatus in FIG. 4;

FIG. 10 is a plan view of an apparatus similar to that in FIG. 4,configured so as to process discrete groups of containing cavities;

FIG. 11 is a schematic side view of an apparatus for separating singlecontainers from a sheet material;

FIG. 12 is a schematic plan view showing a detail of a conveyor belt ofthe apparatus in FIG. 11;

FIG. 13 is a side view of an apparatus similar to that in FIG. 11,showing a control device included in the apparatus;

FIG. 14 is a side view of a first portion of an apparatus for applying aclosing film to a plurality of containing cavities, according to analternative embodiment;

FIG. 15 is a side view of a second portion of the apparatus in FIG. 14;

FIG. 16 is a plan view showing a positioning device for positioning aremoving element on the closing film, included in the apparatus in FIG.14;

FIG. 17 is a side view of the positioning device in FIG. 16;

FIG. 18 is an enlarged and fragmentary side view showing a joiningdevice for joining the removing element to the closing film;

FIG. 19 is a schematic plan view showing a removing element joined tothe closing film;

FIG. 20 is a diagram showing a forming apparatus, a welding apparatusand a separating apparatus integrated into a production line;

FIG. 21 is a diagram like that in FIG. 20, showing an alarm situation.

DETAILED DESCRIPTION

FIGS. 1 and 2 show a forming apparatus 1 for forming on a sheet material2 a plurality of containing elements having the shape of containingcavities 3. The sheet material 2 is a thermoformable and weldablematerial and can comprise, for example, a film of plastics. The sheetmaterial 2 is unwound from a reel 4 and indexed by an advancing devicealong an advancing direction F1. The advancing device comprises a firstgripper 5 and a second gripper 6 arranged in sequence along theadvancing direction F1. The first gripper 5 and the second gripper 6each comprise a lower gripping element 7 and an upper gripping element8, at least one of which is movable in a clamping direction Y that istransverse to the advancing direction F1, and which are arranged onopposite parts of the sheet material 2. In particular, the lowergripping element 7 and the upper gripping element 8 are movable inrelation to one another between a disengaging position shown in FIG. 1,in which the sheet material 2 is disengaged from the lower grippingelement 7 and from the upper gripping element 8, and a clamping positionthat is not shown, in which the sheet material 2 is clamped between thelower gripping element 7 and the upper gripping element 8. In theclamping position, the first gripper 5 and the second gripper 6 can movealong the advancing direction F1 to move the sheet material 2 inside theforming apparatus 1.

In the example shown, the sheet material 2 advanced by the first gripper5 and by the second gripper 6 defines a substantially horizontal plane.

The forming apparatus 1 comprises, downstream of the first gripper 5, apreheating station 9 for heating the sheet material 2 to a temperatureat which the sheet material 2 is softened and can be easilythermoformed. The preheating station 9 comprises a lower plate 10 and anupper plate 11 that are movable transversely to the advancing directionF1, as indicated by the arrows Y1, to bring close and heat the sheetmaterial 2 whilst it is stationary in the preheating station 9.

Downstream of the preheating station 9, which with certain types ofsheet material 2 can be omitted, there is provided a forming station 12comprising a male half mould 13 and a female half mould 14 interactingtogether to form on the sheet material 2 the containing cavities 3, forexample by thermoforming. The male half mould 13 and the female halfmould 14 are also movable transversely to the advancing direction F1, asindicated by the arrows Y2, so as to move towards or away from the sheetmaterial 2.

Downstream of the forming station 12 there is a separating device 15,comprising, for example, a blade 16, cooperating with an abuttingelement 17 for cutting the sheet material 2 along a line that istransverse, for example perpendicular, to the advancing direction F1.The blade 16 and the abutting element 17 are positioned on oppositeparts of the sheet material 2. In the example shown, the blade 16 isarranged below the sheet material 2, whilst the abutting element 17 ispositioned above the sheet material 2. The blade 16 may have the shapeof a disc and is rotatable around a rotation axis R that issubstantially parallel to the advancing direction F1. A movement devicethat is not shown moves the blade 16 transversely to the advancingdirection F1, more in particular perpendicularly to this direction, sothat the rotation axis R is maintained parallel to itself. In thismanner groups 18 of containing cavities are separated from the sheetmaterial 2, one of the groups 18 of containing cavities being shown inFIG. 3, including a plurality of containing cavities 3 joined togetherby a flat portion 19 of sheet material 2.

The forming apparatus 1 further comprises an activating device that isnot shown for selectively activating or deactivating the separatingdevice 15. If the separating device 15 is deactivated, i.e. notoperating, a continuous strip of containing cavities 3 exits from theforming apparatus 1. In this case, the forming apparatus 1 can beinserted into an automated line to produce filled and closed containersfrom a continuous sheet material. Downstream of the forming apparatus 1a filling unit will therefore be arranged that is followed by otheroperating units.

If, on the other hand, the separating device 15 is activated, theforming apparatus 1 produces the groups 18 of containing cavities, whichcan be temporarily stored, or processed manually before undergoing otherpossible automated operations. For example, the groups 18 can be filledmanually with a desired product. In this case, the forming apparatus 1is not integrated into a continuous production line, but operates inisolation.

FIGS. 4 to 6 show a welding apparatus 21 for applying a closing film 22to a plurality of containing cavities 3. The containing cavities 3 wereformed previously on a sheet material 2, for example by the formingapparatus 1 shown in FIGS. 1 and 2, and then filled with a desiredproduct 20.

The closing film 22 can be a film of plastics that is unwound from arespective reel 23, as shown in FIGS. 4 and 5, and indexed along asupply direction F2. Whilst it advances along the supply direction F2,the closing film 22 defines a substantially horizontal plane.

The welding apparatus 21 comprises a cutting station 24, including acutting device acting on the closing film 22 to remove preset portionstherefrom. The cutting device comprises a supporting element 25 on whichare mounted one or more shearing members 26 having a cutting profilecorresponding to the shape of the portions that it is desired to removefrom the closing film 22. In the example shown in FIG. 5, on thesupporting element 25 two shearing members 26 are mounted that haverespective substantially quadrilateral cutting profiles.

The cutting device further comprises an abutting base 28, positioned onthe side of the closing film 22 opposite the supporting element 25 andinteracting with the shearing members 26 during cutting.

As indicated by the arrow V1, the supporting element 25 is slidablealong columns 27 that project from the abutting base 28 transversely tothe supply direction F2, in particular perpendicularly to thisdirection. In this manner the supporting element 25 can move between arest position, shown in FIG. 5, in which the shearing members 26 aredistanced from the closing film 22, and a work position that is notshown, in which the shearing members 26 are in contact with the abuttingbase 28 to remove the portions of closing film 22, so as to define onthe closing film 22 a plurality of openings 29.

The cutting station 24 comprises an adjusting device for adjusting theposition of the cutting device along the supply direction F2. Theadjusting device may comprise one or more guide elements 30 along whichthe abutting base 28, together with the columns 27 and the supportingelement 25, is slidable, as indicated by the arrow X1. The guideelements 30 extend parallel to the supply direction F2.

The abutting base 28, the columns 27 and the supporting element 25 canbe moved along the guide elements 30 manually or automatically, forexample by a driving device that may comprise an actuator that is notshown. A locking device that is not shown enables the cutting device tobe fixed in the desired position along the guide elements 30, after theadjusting operations have been performed.

The reason for which the adjusting device is provided will be disclosedin detail below.

The welding apparatus 21 further comprises an operating unit including awelding station 31 that enables the closing film 22 to be welded to thesheet material 2, so as to close the containing cavities 3. The weldingstation 31 is positioned along a portion 102 of the path of the sheetmaterial 2 that, in the example shown, extends in a conveying directionF3 that is substantially perpendicular to the supply direction F2.

A direction-switching device enables the closing film 22 to be switchedfrom the supply direction F2 to the conveying direction F3. Thedirection-switching device comprises a plurality of rollers, including adirection-switching roller 32, shown in FIG. 4, that is rotatable aroundan axis H that lies on a horizontal plane and is tilted by 45° withrespect to the supply direction F2.

A coupling roller 33, shown in FIGS. 4 and 6, is arranged downstream ofthe direction-switching device and enables the closing film 22 to bebrought into contact with the sheet material 2.

The sheet material 2, arranged in contact with the closing film 22, isindexed through the welding station 31 by a conveying device comprisinga gripper 35 and a further gripper 36, which are completely similar tothe first gripper 5 and to the second gripper 6 disclosed with referenceto FIGS. 1 and 2.

As shown in FIG. 6, the welding station 31 comprises a coupling deviceincluding a lower plate 34 interacting with an upper plate 37. On thelower plate 34 a plurality of recesses 38 are obtained that are suitablefor receiving the containing cavities 3 obtained on the sheet material2. The upper plate 37 on the other hand supports a heated weldingelement 39 and a non-heated stabilising element 40, shown in FIG. 6.

The upper plate 37 and the lower plate 34 are moveable transversely tothe conveying direction F3, as indicated by the arrows V2, between adistanced position shown in FIG. 6 and a contact position that is notshown. In the distanced position, the lower plate 34 and the upper plate37 are distanced from the sheet material 2 and from the closing film 22,which can advance freely in the conveying direction F3. In the contactposition, the sheet material 2 and the closing film 22 are clampedbetween the lower plate 34 and the upper plate 37 to join the closingfilm 22 to the sheet material 2 along edge zones 41 surrounding thecontaining cavities 3. In particular, the heated welding element 39applies the heat and the pressure that enable the closing film 22 to bewelded to the sheet material 2, whilst the non-heated stabilisingelement 40, arranged downstream of the heated welding element 39,applies pressure to stabilise the weld that has just been formed.

In the case disclosed above, the welding station 31 thus acts as athermowelding station, inasmuch as it thermowelds the closing film 22 tothe sheet material 2, i.e. couples the closing film 22 with the sheetmaterial 2 owing to the combined action of heat and pressure. In oneembodiment that is not shown, the welding station 31 can also operateaccording to a different principle. For example, the welding station 31can comprise an ultrasound welding device that enables the closing film22 to be joined to the sheet material 2.

Downstream of the welding station 31 a separating device 45 is arrangedwhich is completely analogous to the separating device 15 disclosed withreference to FIGS. 1 and 2. If the separating device 45 is activated, itenables discrete groups of containing elements, each containing elementcomprising a containing cavity 3 filled with the product 20 and closedby a portion of closing film 22, to be separated from a continuous stripof sheet material 2, to which a continuous closing film 22 has beenwelded.

The adjusting device included in the cutting station 24 enables theopenings 29 to be obtained on the closing film 22 in a desired positionso that, when the closing film 22 is coupled with the sheet material 2,the openings 29 are positioned at preset zones of the sheet material 2that it is desired should be devoid of the closing film 22. This can beuseful if it is desired to obtain containers of the type shown in FIGS.7 and 9.

FIG. 7 is a plan view that shows a container 42 comprising a containingbody 43 obtained from the sheet material 2 and having a containingcavity 3. The containing body 43 is closed by a closing portion 44obtained from the closing film 22 and joined to the containing body 43along an edge zone 41 that surrounds the containing cavities 3. Thecontaining body 3 is provided with an opening tab 46 that projects fromthe edge zone 41.

The openings 29 are positioned on the closing film 22 so that theclosing film 22 covers only partially the opening tab 46, in which it ispossible to define an uncovered zone 47 in which the closing film 22 isabsent. The uncovered zone 47 corresponds to a zone of the closing film22 in which an opening 29 has been obtained.

In the opening tab 46 it is moreover possible to define a coupling zone48, in which the closing film 22 is coupled with the sheet material 2.The uncovered zone 47 is complementary to the coupling zone 48.

In a region in which the opening tab 46 is connected to the edge zone41, on the sheet material 2 there is obtained an intended separatingline 49, comprising for example a continuous or interrupted notch or cuthaving the object of causing the sheet material 2 to break along theintended separating line 49 when subjected to stress. The intendedseparating line 49 can be obtained when the sheet material 2 isprocessed by the forming apparatus 1, for example in the forming station12.

As shown in FIG. 8, the container 42 can be joined to a second container42′ of a similar shape to form a packaging unit 50, in which the closingportion 44 is in contact with the corresponding closing portion 44′ ofthe second container 42′. The two containers are joined together along aperipheral zone of the respective closing portions. In order to separatethe two containers, the consumer grasps the opening tab 46 of thecontainer 42 and the corresponding opening tab 46′ of the secondcontainer 42′ and pulls the two opening taps so as to move one containeraway from the other one.

In order to enable the two adjacent containers to be separated from oneanother, it is necessary for the respective opening tabs not to beattached to one another. This is made possible by the uncovered zone 47of the container 42 and by the corresponding uncovered zone 47′ of thesecond container 42′. In fact, at the uncovered zones 47 and 47′ theclosing films 22 of the containers do not come into contact with oneanother, which ensures that the opening tabs 46 and 46′ are not attachedto one another whilst the container 42 is joined to the second container42′. This may, for example, occur because the closing film 22 that formsthe closing portions 44 and 44′ is thermoweldable, whilst the sheetmaterial 2 that forms the containing cavities is not. A possiblethermowelding station that welds the container 42 to the secondcontainer 42′ does not therefore join the uncovered zones 47 and 47′ toone another.

After the container 42 has been separated from the second container 42′,the consumer can open the container 42 by grasping the opening tab 46and pulling the opening tab 46 to the side opposite the containingcavity 3. In this manner, the sheet material 2 is broken along theintended separating line 49, but the closing film 22 remains joined tothe opening tab 46 in the coupling zone 48. By acting further on theclosing tab 46, the consumer can thus remove the closing film 22 fromthe containing body 43, owing to a peeling action of the closing film 22along the edge zone 41.

FIG. 9 shows a container 142 comprising a containing cavity 103 obtainedon the sheet material 2. Outside the containing cavity 103, on the sheetmaterial 2 a protrusion 51 is further provided that projects from a face52 of the sheet material 2. The face 52 is opposite a further face 53 ofthe sheet material 2 from which the containing cavity 103 projects.

The protrusion 51 may, for example, be used to couple the container 142with another container that is not shown if it is desired to obtain acomplex packaging unit. The protrusion 51 can be formed in the formingstation 12 of the forming apparatus 1.

On the closing film 44 an opening 29 is obtained that is positioned atthe protrusion 51, so that the protrusion 51 passes through the opening29 and protrudes from the closing film 44.

In one embodiment, both the protrusion 51 and the opening tab 46 shownin FIG. 7 can be present on the same container.

Before starting to produce containers of the type shown in FIGS. 7 and9, in the cutting station 24 the position of the cutting device alongthe supply direction F2 is adjusted by acting on the adjusting device.In this manner it is ensured that the shearing members 26 obtain theopenings 29 on the closing film 44 in a position corresponding to thatof the protrusions 51 or of the zones of the sheet material 2 intendedfor giving rise to the opening tabs 46.

During operation, after possibly adjusting the position of the cuttingdevice included in the cutting station 24, the closing film 22 isunwound from the respective reel 23 and indexed along the supplydirection F2. The closing film 22 passes through the cutting station 24,in which the openings 29 are obtained. Simultaneously, the sheetmaterial 2 on which the containing cavities 3 are obtained, alreadyfilled with the product 20, is indexed along the conveying direction F3.

The closing film 22, after being switched from the supply direction F2to the conveying direction F3 by means of the direction-switchingdevice, including the direction-switching roller 32, is imposed on thesheet material 2 and joined thereto in the welding station 31, so as toclose the containing cavities 3.

After the closing film 22 has closed the containing cavities 3 in thewelding station 31, the separating device 45, if activated, can cut theclosing film 22 and the sheet material 2, so as to separate discretegroups of containing cavities 3 closed by the closing film 22. Thediscrete groups that are thus obtained can be subsequently stored or beprocessed manually, or yet be conveyed to another place to be subjectedto subsequent processing.

In one embodiment that is not shown, the welding station 31 and thecutting station 24 can be arranged according to a layout that isdifferent from that shown in FIG. 4, for example aligned along a commondirection.

FIGS. 4 to 6 show a configuration in which the welding apparatus 21processes a continuous sheet material 2 on which the containing cavities3 are obtained. In particular, the welding station 31 enables theclosing film 22 to be joined to the continuous sheet material 2, whichclosing film 22 is unwound from the respective reel 23 so as to closethe containing cavities 3. In this configuration, the welding apparatus21 can be inserted into a production line of containers, for exampledownstream of a filling unit positioned outside the forming apparatus 1shown in FIGS. 1 and 2.

If the welding apparatus 21 is inserted into a production line, thewelding apparatus 21 is used for industrial production of largequantities of containers.

Alternatively, the welding apparatus 21 can be used in isolation, forexample by manually supplying the welding apparatus 21 with discretegroups of containing cavities 3. Such discrete groups can be obtained bymanually filling groups 18 of containing cavities, of the type shown inFIG. 3, with the product 20.

In order to process without drawbacks the discrete groups of containingcavities 3, the welding apparatus 21 comprises a control device forchecking whether, whilst the welding station 31 is processing a group ofcontaining cavities 3, a subsequent group of containing cavities 3 is ina preset position upstream of the welding station 31 and is waiting tobe processed. The control device comprises a sensor element, for examplea photocell 54, shown in FIG. 4, arranged along the portion 102 of thepath of the conveying device that conveys the groups of containingcavities 3 to the welding station 31. The sensor element can bepositioned upstream of the region of the conveying device in which theclosing film 22 is brought near the sheet material 2, so as not to beinfluenced by the closing film 22.

The operation of the sensor element will be disclosed in detail withreference to FIG. 10, which illustrates a welding apparatus 21 that iscompletely analogous to the welding apparatus shown in FIG. 4, in aconfiguration in which the welding apparatus 21 processes discretegroups of containing cavities 3. The parts of the welding apparatus 21shown in FIG. 10 that are analogous to those in FIGS. 4 to 6 areindicated by the same reference numbers and are not disclosed in detail.

The welding apparatus 21 comprises a conveying device including an inletconveyor 98 arranged for conveying discrete groups 118 of containingcavities 3, filled with the product 20, in an inlet direction F5 thatmay be transverse to the conveying direction F3. In the example shown,the inlet direction F5 is perpendicular to the conveying direction F3.

The discrete groups 118 thus move along a path that comprises, upstreamof the portion 102 that passes through the welding station 31, a furtherportion 122 defined by the inlet conveyor 98. The further portion 122 istransverse, in particular perpendicular, to the portion 102.

The inlet direction F5 can be parallel and opposite the supply directionF2 along which the closing film 22 is advanced. In this case the weldingapparatus 21 is arranged according to a “T”-shape layout.

The inlet conveyor 98, which can be of the belt type, can comprise aplurality of dividing elements 99 that define on the inlet conveyor 98corresponding housings 100. Each housing 100 has dimensions that aresuch as to receive a single discrete group 118. Each dividing element 99can comprise a bar fixed to the inlet conveyor 98 and extending in adirection that is transverse, in particular perpendicular, to the inletdirection F5.

Each discrete group 118 comprises, in the example shown, two rows ofcontaining cavities 3, each row including eight containing cavities 3.Each discrete group 118 has a greater or longitudinal dimension L and alesser or transverse dimension W. The discrete groups 118 are positionedon the inlet conveyor 98, for example manually, so that the greaterdimension L is transverse, in particular perpendicular, to the inletdirection F5.

A drive device 101 drives the inlet conveyor 98 so that the discretegroups 118 are indexed in the inlet direction F5.

The conveying device further comprises a transferring device, which isnot shown and is arranged for removing the discrete group 118 positionedin the most advanced position PA of the inlet conveyor 98 andtransferring the discrete group 118 to the portion 102. Along theportion 102, which in the example shown is rectilinear, the weldingstation 31 is arranged.

The transferring device can comprise a transferring gripper, similar tothe gripper 35 and to the further gripper 36, or a thrust devicesuitable for pushing the discrete group 118 positioned in the mostadvanced position PA to the gripper 35.

The sensor element, comprising, for example, the photocell 54, ispositioned along the path of the inlet conveyor 98 so as to detect thepresence of a discrete group 118 in the most advanced position PA. Inparticular, the sensor element is positioned in an intersecting zone inwhich the path of the inlet conveyor 98 along the inlet direction F5,i.e. the further portion 122, intersects the portion 102 that extendsalong the conveying direction F3. In this manner the sensor elementenables a discrete group 118 to be detected, on the inlet conveyor 98,that is ready to be advanced in the conveying direction F3.

The sensor element is positioned so as to detect a front zone of thediscrete group 118 in the most advanced position PA, with respect to theconveying direction F3. In the example shown, the sensor element ispositioned near a containing cavity 3 nearer the gripper 35.

During operation, an operator manually positions the discrete groups 118of containing cavities 3, already filled with the product 20, in thecorresponding housings 100 of the inlet conveyor 98. The latter indexesthe discrete groups 118 in the inlet direction F5. The removing deviceremoves the discrete group 118 arranged on the inlet conveyor 98 in themost advanced position PA with respect to the inlet direction F5 andtransfers this discrete group to the portion 102, along the conveyingdirection F3. The discrete group 118 is then grasped by the gripper 35,which conveys the discrete group 118 to the welding station 31, in whichthe closing film 22, which may have openings 29, will be joined to thediscrete group 118.

The sensor element is connected to a control unit that controls theoperation of the welding apparatus 21. If, whilst the welding apparatus21 is operating, the sensor element detects the presence of a discretegroup 118, the control unit enables the welding station 31 to operateregularly, i.e. without interruption. Subsequent discrete groups 118that are constantly detected by the sensor element in fact imply thatthe discrete groups 118 are supplied without interruption to the weldingstation 31, as if these groups formed a continuous strip of containingcavities. The welding apparatus 21 can thus act as disclosed previouslywith reference to FIGS. 4 to 6.

If, on the other hand, the sensor element does not detect the presenceof a discrete group 118, the control unit connected to the sensorelement arrests the welding station 31. Simultaneously, also the cuttingstation 24 and the unwinding of the closing film 22 from the respectivereel 23 are stopped. The welding apparatus 21 thus remains stationaryuntil a discrete group 118, for example positioned manually by anoperator, is detected by the sensor element.

In an alternative embodiment, the control unit can be programmed in sucha manner that, if the sensor element does not detect the presence of adiscrete group 118, the welding apparatus 21 is not immediatelyarrested. The drive device 101 continues to move the inlet conveyor 98for a preset period of time, during which the sensor element can detectthe possible presence of a subsequent discrete group 118. If no discretegroup 118 is detected in the preset interval of time the weldingapparatus 21 is stopped.

If it is desired that the welding apparatus 21 process a continuousstrip of containing cavities 3, as shown in FIGS. 4 to 6, the sensorelement can be disabled. Further, the inlet conveyor 98 can bedismantled or deactivated and the welding apparatus 21 can be suppliedwith a continuous strip of containing cavities 3 conveyed along theconveying direction F3, as shown in FIG. 4.

In this manner, a very versatile welding apparatus 21 is obtained thatcan pass easily from the production of large batches of containers tothe production of small quantities of containers forming discretegroups, and vice versa.

It is understood that the cutting station 24 can also be inserted insidea welding apparatus that is permanently integrated into a continuousproduction line of containers, this apparatus being devoid of sensorelement, including the photocell 54. On the other hand, the sensorelement including the photocell 54 can also be used in a weldingapparatus that does not obtain openings in the closing film and in whichthe cutting station 24 is thus absent.

FIG. 11 schematically shows a separating apparatus 61 for separatingfrom a portion 59 of flat material 62 single containing elementscomprising containers 42. The containers 42 are obtained by filling withthe product 20 the containing cavities 3, formed for example from theforming apparatus 1, and subsequently closing the cavities with theclosing film 22, applied, for example, by the welding apparatus 21. Theflat material 62 comprises the sheet material 2 coupled with the closingfilm 22. The flat material 62 is arranged on a substantially horizontalplane.

The portion 59 of flat material 62 can have a continuous form, in whichcase the separating apparatus 61 processes a continuous strip ofcontainers 42, or have a discrete form, in which case the separatingapparatus 61 processes discrete groups of containers 42, as will bedisclosed in greater detail below. In the case shown in FIG. 11, theportion 59 of flat material 62 is a continuous portion.

The separating apparatus 61 comprises a conveying device, including, forexample, a conveyor belt 55 wound on at least a pair of pulleys 56 toadvance the portion 59 of flat material 62 in a conveying direction F4.The conveying device further comprises a pair of conveying grippers 57,arranged for grasping the flat material 62 conveyed by the conveyor belt55 and for conveying the flat material 62 to an operating unitcomprising a shearing station 58. The conveying grippers 57 arepositioned opposite one another to grasp two opposite strips of the flatmaterial 62. In FIG. 11 only the conveying gripper 57 is visible that isarranged in front of the flat material 62. This gripper hides theconveying gripper 57 arranged behind the flat material 62, which is thusnot visible.

The conveying grippers 57 are movable between a grasping configurationin which they grasp the side edges of the flat material 62 to index theflat material 62 to the shearing station 58 along the conveyingdirection F4, and a free configuration, in which the conveying grippers57 do not engage with the flat material 62 and are free to move parallelto the conveying direction F4 with respect to the flat material 62.

The shearing station 58 comprises a lower half mould 60 and an upperhalf mould 63, arranged on opposite sides of the flat material 62. Thelower half mould 60 and the upper half mould 63 are movable transverselyto the conveying direction F4, as indicated by the arrows V4, between ashearing position that is not shown and a non-operating position shownin FIG. 11. In the non-operating position, the lower half mould 60 andthe upper half mould 63 are spaced apart from one another in such a waythat the flat material 62 can be moved through the shearing station 58.In the shearing position, the lower half mould 60 and the upper halfmould 63 are mutually in contact to separate the containers 42 from theflat material 62.

In the thickness of the lower half mould 60 at least one passage 64 isobtained, i.e. a through opening having dimensions such as to be able tobe traversed by a container 42 after the latter has been separated fromthe flat material 62, for the reasons that will be disclosed below.

The upper half mould 63 is provided with shearing blades 65, arrangedalong a desired profile along which each container 42 will be cut. Theupper half mould 63 further comprises at least a stem 66, passingthrough the thickness of the upper half mould 63, each stem 66 beingmovable transversely to the conveying direction F4, in particularperpendicularly to this direction, as indicated by the arrow V4. Thestroke of the stems 66 is greater than the stroke of the upper halfmould 63. The stems 66 have respective lower ends that can be providedwith gripping elements that are not shown, for example suction cups. Thegripping elements enable the containers 42 to be retained whilst thelatter are moved by the stems 66.

Below the shearing station 58 a conveying device is movable that may,for example, comprise a conveying belt 67 for conveying to the shearingstation 58 a plurality of collecting trays 68 intended for receiving thecontainers 42. The conveyor belt 67 is wound on respective pulleys 69that move the conveyor belt 67 parallel to the conveying direction F4.The conveyor belt 67 has an external surface 70 on which referenceelements 71 are arranged to enable the collecting trays 68 to bepositioned correctly on the conveyor belt 67. The reference elements 71protrude from the external surface 70 and are distributed in anequidistant manner along the conveyor belt 67. In the example shown, thedistance between two consecutive reference elements 71 is substantiallythe same as the length of a collecting tray 68 in the conveyingdirection F4. As shown in FIG. 12, the reference elements 71 have theshape of elongated elements, for example a square or rectangular crosssection, that extends for a significant fraction of the width of theconveyor belt 67, said width being measured transversely to theconveying direction F4. The reference elements 71 can thus be shaped asslats, which can be attached to the external surface 70 of the conveyorbelt 67 for example via screws or adhesive substances.

Each collecting tray 68 comprises a body 72, having a resting surface 73suitable for being rested on the conveyor belt 67, that can be, forexample, substantially flat. In the body 72 a plurality of seats 74 areobtained, each seat 74 being intended for housing a container 42. Whenthe collecting tray 68 is below the shearing station 58, the containers42 are dropped into the seats 74 until they fill the entire collectingtray 68. The collecting tray 68 that is thus filled enables thecontainers 42 to be handled more easily, for example to convey thecontainers 42 to subsequent processing zones or to store the containers42.

In one embodiment, the collecting tray 68 can also comprise a displaystand inside which the containers 42 are housed whilst they are in ashop to be sold.

Along the path of the conveyor belt 67 a detecting device can also beprovided, for example a photocell detector 76, that detects the passageof the reference elements 71. The photocell detector 76 is connected toa control unit that controls the operation of the separating apparatus61 and enables the position of the conveyor belt 67 to be adjusted inrelation to the conveyor belt 55, so that the seats 74 of the collectingtrays 68 are arranged at the containers 42.

The separating apparatus 61 further comprises an outlet conveyor 75,positioned downstream of the shearing station 58 and movable in theconveying direction F4 to move to a disposal zone that is not shown theflat material 62, after the containers 42 have been separated from thelatter.

Before the separating apparatus 61 starts to separate the containers 42,the photocell detector 76 detects the position of the reference elements71 arranged along the conveyor belt 67 and communicates this position tothe control unit. The control unit processes the position of theconveying elements 71 and, on the basis of the type of collecting trays68 used, calculates the position of the seats 74. If necessary, thecontrol unit moves the conveyor belt 68 so as to move the conveyingelements 71 to a preset position in which the seats 74 are belowpassages 64 when the corresponding containers 42 are separated from theflat material 62. In this manner, each container 42 can fall preciselyinside a seat 74.

During operation, the conveyor belt 55 advances the containers 42,joined by the flat material 62, in the conveying direction F4. In thecase shown in FIG. 11, in which the separating apparatus 61 isintegrated into a production line of containers and processes acontinuous strip of flat material 62, the flat material 62 that entersthe separating apparatus 61 can come directly from the welding apparatus21.

Whilst the conveyor belt 55 advances the containers 42, joined by theflat material 62, the conveyor belt 67 indexes the collecting trays 68,which have been previously positioned on the conveyor belt 67, forexample manually. The reference elements 71 ensure that the collectingtrays 68 are positioned correctly on the conveyor belt 67, so that eachseat 74 is in step with a corresponding container 42.

At the conveyor belt 55 outlet, the conveying grippers 57 grasp the twoopposite longitudinal edges of flat material 62 and indexes thecontainers 42 in the shearing station 58. When the containers 42 arestationary in the shearing station 58, the lower half mould 60 and theupper half mould 63 are taken to the shearing position, in which theshearing blades 65 separate the single containers 42 from the flatmaterial 62. The stems 66 slide downwards so that the gripping elementsfixed to the stems 66 engage with the containers 42 before the latterare separated from the flat material 62.

After the containers 42 have between separated from the flat material62, the stems 66, the gripping elements of which still retain thecontainers 42, move further downwards so as to move the containers 42 tocorresponding seats 74 of a collecting tray 68 underneath. When thestems 66 have taken the containers 42 near the collecting tray 68, thegripping elements release the containers 42 in the seats 74.

Subsequently, the lower half mould 60 and the upper half mould 63 moveaway from one another, and the flat material 62, from which thecontainers 42 have been separated, is conveyed to the disposing zone bythe outlet conveyor 75. The collecting trays 68, after being filled withthe containers 42, are moved way from the shearing station 58 by theconveyor belt 67 and are then taken away by the operator.

FIG. 13 shows a separating apparatus 161 that is similar to theseparating apparatus 61 shown in FIG. 11. FIG. 13 highlights the controldevice that enables the separating apparatus 161 both to processcontinuous strips of containers 42 and to process discrete groupscomprising a preset number of containers 42 joined together by the flatmaterial 62.

It is understood that the control device that will be disclosed belowwith reference to FIG. 13 can also be included in the separatingapparatus 61 shown in FIG. 11, in order to enable the apparatus toprocess discrete groups of containers 42.

The parts of the separating apparatus 161 that are analogous to parts ofthe separating apparatus 61 are indicated by the same reference numbersand are not again disclosed in detail.

The control device comprises a sensor element arranged along a path 132of the conveyor belt 55 upstream of the shearing station 58.

The sensor element comprises a detector 104, comprising for example aphotocell, positioned immediately upstream of the shearing station 58with respect to the conveying direction F4. The detector 104 is used todetect the presence of a first discrete group of containers in a presetposition, when the separating apparatus 161 is started up to start toseparate containers from the flat material 62.

The sensor element further comprises a sensor 105, including for examplea photocell, arranged upstream of the shearing station 58 with respectto the conveying direction F4. The sensor 105 is positioned upstream ofthe detector 104 and is spaced away from the latter. The distancebetween the detector 104 and the sensor 105 may be greater than thelength of each discrete group of containers, measured in the conveyingdirection F4. The sensor 105 is used to detect whether, immediatelyafter a discrete group of containers has been advanced downstream of thesensor 105 to be processed in the shearing station 58, a subsequentdiscrete group of containers is available for being advanced to theshearing station 58.

The separating apparatus 161 further comprises a stopping device forstopping the discrete groups of containers in one or more presetpositions. The stopping comprises device a stopping element forstopping, in a preset position, the first discrete group of containersthat enters the separating apparatus 161 when the latter is started up.The stopping element is movable between a stop position, in which thestopping element prevents the first discrete group of containers fromcontinuing along the conveying direction F4, and a passage condition inwhich the stopping element does not hamper the passage of the firstdiscrete group of containers. In the example shown, the stopping elementcomprises a stem of an actuator 106, for example of hydraulic orpneumatic type. The stopping element is arranged near the sensor 105.More precisely, the stopping element is arranged immediately downstreamof the sensor 105 with respect to the conveying direction F4.

The stopping device further comprises a stopping device for stopping, ina preset position upstream of the shearing station 58, discrete groupsof containers that follow a discrete group that has already beenadvanced downstream of the actuator 106. The stopping device maycomprise an actuator cylinder 107, of hydraulic or pneumatic type,having a stem that is movable between a stop position and a passageposition.

The actuator cylinder 107 can be positioned immediately downstream ofthe actuator 106 along the conveying direction F4.

When the separating apparatus 161 is started up for the first time, nodiscrete group of containers is present in the shearing station 58 oralong the conveyor belt 55. Consequently, the detector 104 does notdetect the presence of any group of containers. This information istransmitted to a control unit connected to the sensor element. Thecontrol unit commands the actuator 106, the stem of which is moveddownwards, i.e. is made to emerge outside the actuator 106. In thismanner the stem of the actuator 106 is positioned in the stop position.

Subsequently, the conveyor belt 55 is moved to convey along theconveying direction F4 discrete groups of containers, which arepositioned by an operator on the conveyor belt 55. The conveyor belt 55can be moved continuously during the entire period of operation of theseparating apparatus 161.

When the first discrete group of containers conveyed by the conveyorbelt 55 arrives at the sensor 105, the latter detects the presencethereof. Simultaneously, the first discrete group of containers comes toabut against the stem of the actuator 106 and stops at a preciseposition determined by this stem. In this position, the conveyinggrippers 57 grasp the first discrete group of containers and the stem ofthe actuator 106 is retracted to the passage position to enable theconveying grippers 57 to convey the first discrete group of containersto the shearing station 58.

Subsequently, the first discrete group of containers, moved by theconveying grippers 57, arrives at the detector 104, which detects thepresence thereof. When the control unit is informed that the firstdiscrete group of containers has been detected by the detector 104, theactuator 106 is deactivated, so that the stem thereof remains in thepassage position. The actuator cylinder 107 is on the other handactivated and the stem of the actuator cylinder 107 is moved outside theactuator cylinder 107, i.e. downwards, so as to reach the respectivestopping position. The second discrete group of containers conveyed bythe conveyor belt 55 passes below the actuator 106, the stem of which isin the passage position, and stops against the stem of the actuatorcylinder 107, which is in the stop position. The second discrete groupof containers now acts as a stopping element that stops the thirddiscrete group of containers conveyed by the conveyor belt 55.

In the meantime, the detector 105 has detected the presence of thesecond discrete group of containers. Consequently, the stem of theactuator cylinder 107 can be retracted to the respective passageposition and the second discrete group of containers can be grasped bythe conveying grippers 57 and conveyed to the shearing station 58.

As long as the discrete groups of containers continue to be positionedon the conveyor belt 55 and conveyed by the conveyor belt 55, on afteranother, in the conveying direction F4, the sensor 105 continues todetect the presence of discrete groups of containers and maintains thestem of the actuator cylinder 107 in the passage position. The discretegroups of containers are thus advanced without interruptions to theshearing station 58, which process the discrete groups of containers, asif interacting themselves with a continuous strip of containers.

When the discrete groups of containers are no longer positioned oneafter another on the conveyor belt 55, for example because the operatorno longer has discrete groups to be loaded onto the conveyor belt 55,the sensor 105 no longer detects the presence of discrete groups ofcontainers. Consequently, the actuator cylinder 107 is commanded so asto take the respective stem to the stop position and operation of theseparating apparatus 161 is temporarily interrupted.

The actuator cylinder 107 remains in the stop position until the momentin which a subsequent discrete group of containers, moved by theconveyor belt 55, goes to abut against the corresponding stem and isdetected by the sensor 105. At this point, the actuator cylinder 107retracts the stem into the passage position and the discrete group ofcontainers is advanced to the shearing station 58. The separatingapparatus 161 thus resumes operating regularly again.

In conclusion, the detector 104 and the actuator 106 work only in thestartup steps of the separating apparatus 161, in order to ensure thatthe first discrete group of containers is introduced inside theseparating apparatus 161 in a desired position with respect to theshearing station 58. The sensor 105 and the actuator cylinder 107, onthe other hand, work not only at startup but also during operation ofthe apparatus in order to ensure that all the discrete groups ofcontainers are conveyed correctly to the shearing station 58.

In one embodiment, in which the first discrete group of containers ispositioned manually in a desired position upstream of the shearingstation 58, it is possible to use only the sensor 105 and the actuatorcylinder 107, thus eliminating the detector 104 and the actuator 106.

The sensor element and the stopping device enable the separatingapparatus 161 to process discrete groups of containers in a reliablemanner to minimise also in this case manual operations. Naturally, theseparating apparatus 161 can also process a continuous strip ofcontainers, in which case it is sufficient for the control unit todeactivate the sensor element and maintain the stopping devicepermanently in the passage position.

The sensor element and the stopping device disclosed with reference toFIG. 13 can also be provided in the separating apparatus 61 shown inFIG. 11.

In one embodiment, the sensor element and the stopping device can beused in a separating apparatus that does not use the collecting trays68.

FIGS. 14 and 16 show an inlet portion of a welding apparatus 81according to an alternative embodiment. The welding apparatus 81comprises a first supporting element 77 for supporting a first reel 78of closing film 22 and a second supporting element 79 for supporting asecond reel 80 of closing film 22. The second reel 80 acts as a reservereel and enables the welding apparatus 81 downtimes to be minimised oreven to be reduced to zero when the closing film 22 wound on the firstreel 78 finishes.

Naturally, the first supporting element 77 and the second supportingelement 79 can also be used in the welding apparatuses 21 shown in FIGS.4 to 6 and 10.

The closing film 22 is unwound from the first reel 78 by means of knownunwinding device, such as to be on a plane that may be substantiallyhorizontal and then be indexed by an advancing device that is not shownalong a supply direction F12, which can be substantially horizontal.

Downstream of the first reel 78 there may be a cutting station 124 thatenables a plurality of openings to be obtained on the closing film 22that are intended to leave preset zones of the sheet material 2uncovered with which the closing film 22 will be subsequently coupled.The cutting station 124 is similar to the cutting station 24 disclosedwith reference to FIGS. 4 and 5 and can comprise an adjusting device foradjusting the position of the respective cutting device so as to obtainthe openings in the desired positions of the closing film 22.

The cutting station 124 is optional and could be omitted if it is notdesired to obtain the openings on the closing film 22.

The welding apparatus 81 comprises a joining device 82, that can bearranged downstream of the cutting station 124, to join a removingelement to the closing film 22. The removing element can be used by aconsumer who purchases the closed container closed by the closing film22 to remove a substance contained in a containing cavity of saidcontainer, or of a different container. As shown in FIGS. 16 and 19, theremoving element may comprise spoon elements 83, for example having asubstantially flat shape. By using the spoon elements 83, the user caneat a creamy substance contained in the containers that he haspurchased. The spoon elements 83 are made of plastics.

The welding apparatus 81 further comprises a positioning device toposition the spoon elements 83 on the closing film 22. In the exampleshown, the positioning device comprises a first positioning device 108and a second positioning device 109, arranged on two opposite sides ofthe closing film 22. The first positioning device 108 and the secondpositioning device 109 enables two rows of spoon elements 83 to bearranged on the closing film 22 that are arranged symmetrically withrespect to a symmetry axis S of the closing film 22.

In one embodiment, it is possible to provide the positioning device onlyon one side of the closing film 22, if it is desired to position on theclosing film 22 a single row of removing elements 83.

The first positioning device 108 and the second positioning device 109have substantially identical structural components and operating modes.

The first positioning device 108 and the second positioning device 109each include a respective hopper 110 that is filled with a plurality ofspoon elements 83 arranged loosely. From the hopper 110 the spoonelements 83 fall into an orientating device 111 below, from which allthe spoon elements 83 exit with a preset orientation.

The orientation device 111, which is not described in detail because itis of known type, may comprise a vibration device.

From each orientation device 111 two rows of spoon elements 83 emergethat are oriented so that a gripping portion 112 of each spoon element83 precedes a removing portion 113 of the corresponding spoon element83. The gripping portion 112, shown in detail in FIG. 19 is suitable forbeing grasped by the consumer, whilst the removing portion 113 issuitable for removing the desired product 20 from the container.

The pairs of spoon elements 83 emerging from each orientation device 111are subsequently received from a transferring carousel 114 that isrotatable around a vertical rotation axis. Each transferring carousel114, after a rotation of 180°, delivers the pairs of spoon elements 83to a conveying device that is not shown, comprising for example one ormore suction cups or other sucking elements, that positions the spoonelements 83 on the closing film 22 that is stationary in an operationstation comprising the joining device 82.

As shown in FIG. 18, the joining device 82 comprises a first half mold115 and a second half mold 116. The first half mold 115 is arrangedabove the closing film 22, whilst the second half mold 116 is arrangedbelow this film.

The first half mould 115 is provided with protruding elements 117 thatproject to the closing film 22 so as to come into contact with the spoonelements 83 in joining zones 119. Also the second half mould 116comprises projecting elements 120 arranged in positions corresponding tothe protruding elements 117.

The first half mould 115 and the second half mould 116 are movable withrespect to one another, transversely to the supply direction F12,between a distanced configuration shown in FIG. 18 and a contactconfiguration that is not shown. In the distanced configuration, thefirst half mould 115 and the second half mould 116 are spaced apart fromone another so that the closing film 22 can advance freely between thefirst half mould 115 and the second half mould 116. In the contactconfiguration, the closing film 22, together with the spoon elements 83positioned thereupon, is clamped between the protruding elements 117 ofthe first half mould 115 and the projecting elements 120 of the secondhalf mould 116. The protruding elements 117 and possibly also theprojecting elements 120 are heated, so as to thermoweld the spoonelements 83 to the closing film 22 at the joining zones 119.

In an alternative embodiment, the joining device 82 may comprise anultrasound joining device to join the spoon elements 83 to the closingfilm 22 at the joining zones 119 by ultrasound welding.

It is also possible to use a joining device 82 comprising a device forapplying an adhesive substance for gluing spoon elements 83 to theclosing film 22.

The positioning device and the joining device 82 enable the spoonelements 83 to be joined to the closing film 22 in an automated andprecise manner.

FIG. 15 shows a final portion of the welding apparatus 81, arrangeddownstream of the initial portion shown in FIGS. 14 and 16. The finalportion of the welding apparatus 81 is arranged downstream of thejoining device 82 and receives the incoming closing film 22 to which thespoon elements 83 have been joined. This film moves in the supplydirection F12.

By arranging the final portion of the welding apparatus 81 downstream ofthe initial portion along the advancing direction F12, it is avoidedthat the closing film 22 undergoes orientation changes that could detachthe spoon elements 83.

Downstream of the joining device 82, the welding apparatus 81 comprisesa coupling device for coupling by welding the closing film 22 with asheet material 2 on which the containing cavities 3 have been obtainedthat were previously filled with a desired product.

The coupling comprises device a welding station 131, that is completelysimilar to the welding station 31 disclosed with reference to FIGS. 4and 6.

As previously disclosed with reference to the welding apparatuses 21shown in FIGS. 4 to 6 and 10, also the welding apparatus 81 can processboth a sheet material 2 in continuous form on which the containingcavities 3 were formed, and discrete groups 118 of containing cavities3, that were previously separated from a sheet material 2 in continuousform.

For this purpose, the welding apparatus 81 comprises a conveying deviceincluding a transverse conveyor belt that is not shown, that is verysimilar to the conveyor belt 98 shown in FIG. 10, to advance thediscrete groups 118 in an inlet direction that is transverse, forexample perpendicular, to the advancing direction F12. The conveyingdevice may further comprise a transferring gripper 121 for transferringthe discrete groups 118 from the transverse conveyor belt to a gripper135 that is similar to the gripper 35 in FIG. 10.

A control device is further provided that is similar to the controldevice including the photocell 54 in FIG. 10, to check for the presenceof discrete groups 118 that are available for being conveyed to thewelding station 131.

If the welding apparatus 81 processes discrete groups 118 of containingcavities 3, the transverse conveyor belt and the control device areactivated and the final portion of the welding apparatus 81 acts in themanner disclosed with reference to FIG. 10.

If, on the other hand, the welding apparatus 81 processes a continuousstrip of sheet material 2 on which the containing cavities 3 areobtained, the sensor element and the transverse conveyor belt aredisabled and the continuous strip of sheet material 2 is advanced in theadvancing direction F12 and processed without interruptions.

In the preceding description it has been explained several times thatboth the forming apparatus and the welding apparatus and the separatingapparatus can operate in insulation or be integrated into a singleproduction line.

FIG. 20 is a diagram showing a configuration in which the formingapparatus, the welding apparatus and the separating apparatus areintegrated into a line for producing containers. The forming apparatuscan be of the type shown in FIGS. 1 and 2 whilst the welding apparatuscan be of the type shown in FIGS. 4 to 6 or 14 to 19. Lastly, theseparating apparatus can be of the type shown in FIG. 11 or 13.

The forming apparatus has a user interface UI1 connected to a controlunit CU1, which controls the operation of the forming apparatus.Similarly, the welding apparatus has a user interface UI2 connected to acontrol unit CU2, whilst the separating apparatus has a user interfaceUI3 connected to a control unit CU3.

Each of the three control unit CU1, CU2 and CU3 can comprise a PLC. Eachof the three user interfaces UI1, UI2 and UI3 comprises a selectingdevice by means of which an operator can select whether thecorresponding apparatus has to operate in isolation or has to beintegrated into a continuous production line. In the isolated operatingcondition, each apparatus processes discrete groups of containingelements. On the other hand, in the line operating condition, eachapparatus processes a continuous strip of containing elements.

The selecting device may comprise, for each apparatus, a pushbutton IL,which is pressed or selected when it is desired that the apparatusoperates as part of a line, and a pushbutton OL, which is pressed andselected when it is desired that the apparatus operates in isolation.

Each user interface UI1, UI2 and UI3 can also comprise controlpushbuttons by means of which an operator can control the operation ofthe corresponding apparatus. The control pushbuttons may comprise aSTART key, which the operator presses to start up the correspondingapparatus, a STOP key, which the operator presses to stop the apparatus,and a RESET key that is pressed to reset possible anomalous operatingconditions that have arisen in the apparatus.

Each user interface UI1, UI2 and UI3 further comprises a reportingdevice for reporting, for example visually, the operating condition ofthe corresponding apparatus. The reporting device may comprise a greenpilot lamp, included for example in the START pushbutton, whichindicates that the corresponding apparatus is operating correctly. Whenthe operator presses the START pushbutton to start up the correspondingapparatus, this pushbutton shines with a green light and maintains thiscolor for the entire time for which the apparatus continues to operate.

The reporting device may further comprise a red pilot lamp, included,for example, in the STOP pushbutton, that lights up when the apparatusstops because a malfunction condition has occurred. The red pilot lampswitches off when, following the intervention of the operator, themalfunction has been remedied and the apparatus is ready to operate.

The reporting device further comprises a screen 125, included in eachuser interface UI1, UI2 and UI3, on which possible messages aredisplayed relating to the operating status of the correspondingapparatus.

The control units CU1, CU2 and CU3 are connectable together via aconnecting device that may comprise an Ethernet network, or a LANnetwork, or still be of wireless type. In particular, the connectingdevice comprises a first connecting device 126 for connecting thecontrol unit CU2 of the welding apparatus and the control unit CU1 ofthe forming apparatus. The connecting device further comprises a secondconnecting device 127 for connecting the control unit CU2 of the weldingapparatus and the control unit CU3 of the separating apparatus. In oneembodiment, as indicated with a dashed line in FIG. 20, the secondconnecting device 127, rather than connecting the separating apparatusto the welding apparatus, can connect the separating apparatus to theforming apparatus. In this case, the control unit CU2 of the weldingapparatus and the control unit CU3 of the separating apparatus conversetogether via the control unit CU1 of the forming apparatus.

If the operator selects the isolated operating condition, the formingapparatus, the welding apparatus and the separating apparatus operateindependently of one another, as disclosed in detail above. In theisolated operating condition, the connecting device is deactivated, i.e.the control units CU1, CU2 and CU3 do not communicate together. Eachcontrol unit controls only the operation of the respective apparatus. Inparticular, the separating device 15 of the forming apparatus isactivated, so as to separate discrete groups 18 of containing cavities 3from the sheet material 2. The welding apparatus receives incomingdiscrete groups of containing cavities 3, already filled with thedesired product 20, and closes the discrete groups of containingcavities 3 by means of the closing film 22, which is subsequently cut bythe separating device 45. The separating apparatus receives incomingdiscrete groups of containing cavities 3, closed by the closing film 22,and separates the incoming discrete groups of containing cavities 3 fromthe flat material 62 for obtaining single containers 42. The operatorcan read messages relating to the status of the single apparatus on thecorresponding screen 125 and can control the operation of each singleapparatus via the corresponding START, STOP and RESET pushbuttons.

In the isolated operating condition, the forming apparatus, the weldingapparatus and the separating apparatus can be positioned in physicallydifferent places or rooms. A producer may also not possess or notsimultaneously use all three apparatuses, for example because certainoperations are performed manually.

If the line operating condition is selected, the connecting device isactivated in such a way that the control units CU1, CU2 and CU3communicate together. The control unit CU1 of the forming apparatusdeactivates the separating device 15 so that from the forming apparatusa continuous strip of containing cavities 3 that are obtained on thesheet material 2 exits. The containing cavities 3 of the continuousstrip, after being filled with the product 20 by means of a filling unitthat is not shown, enter the welding apparatus, which seals the closingfilm 22 on the continuous strip of containing cavities 3. The separatingdevice 45 included in the welding apparatus were deactivated by thecorresponding control unit CU2. A continuous strip of filled and closedcontaining cavities 3 is then conveyed to the separating apparatus,which separates the containers 42 from this strip.

Each of the three control units CU1, CU2 and CU3 comprises asynchronising device for synchronising the corresponding apparatus withthe other two apparatuses. For this purpose, each of the control unitsCU1, CU2 and CU3 is programmed so as to exchange with the remainingcontrol units information that enables the forming apparatus, thewelding apparatus and the separating apparatus to work in a synchronisedmanner. For example, when the forming apparatus starts to form thecontaining cavities 3, the corresponding control unit CU1 sends anoperation start signal to the control unit CU2 of the welding apparatus.In response to this signal, the control unit CU2 of the weldingapparatus immediately starts operation of the welding apparatus, so thatthe forming apparatus and the welding apparatus work in a synchronisedmanner. In one embodiment, the welding apparatus can start up with acontrolled delay with respect to the forming apparatus, because thesheet material 2, on which the containing cavities 3 were formed in anintermediate zone between the forming apparatus and the filling unit,can form a compensating loop that enables the operation of the formingapparatus and of the welding apparatus to be staggered slightly.

Further, as soon as the welding apparatus starts to operate, the controlunit CU3 of the separating apparatus is duly informed, such as to startup the corresponding welding station immediately. This ensures that theseparating apparatus and the welding apparatus work in a synchronisedmanner.

A similar information exchange also occurs when, for any reason, one ofthe three apparatuses is arrested.

Each of the three control units CU1, CU2 and CU3 is further programmedso as to exchange with the other two control units information relatingto the operating status of the corresponding apparatus, in particulardiagnostic information relating to possible fault conditions that occurin the various apparatuses. In the line operating condition, thisenables the reporting device of the forming apparatus, of the weldingapparatus and of the separating apparatus to be coordinated. In thismanner, when in the forming apparatus, or in the welding apparatus, orin the separating apparatus, a malfunction condition occurs, an errormessage is generated that is displayed simultaneously on all threescreens 125. Simultaneously, if the operating condition is such as todetermine the stop of the corresponding apparatus, the entire productionline stops and on all three user interfaces UI1, UI2 and UI3 the redpilot lamp lights up.

An example of this situation is shown in FIG. 21, which refers to asituation in which, in the welding apparatus, excessive temperature ofthe upper plate 37 and/or of the lower plate 38 shown in FIG. 6 wasdetected. The control unit CU2 of the welding apparatus thus generatesan error message, which can be formulated as “Excessive welding mouldtemperature”. This error message is displayed on the screen 125 of theuser interface UI2 of the welding apparatus. The welding apparatus stopsand the red pilot lamp included in the corresponding STOP pushbuttonlights up.

Simultaneously, the control unit CU2 of the welding apparatus informsthe control unit CU1 of the forming apparatus and the control unit CU3of the separating apparatus, respectively by the first connecting device126 and the second connecting device 127, of the malfunction conditionthat has occurred in the welding station. The control units CU1 and CU3control the corresponding screens 125 so that also on these screens theerror message is displayed relating to the problem that has occurred inthe welding apparatus. Simultaneously, the forming apparatus and theseparating apparatus are arrested and on the corresponding userinterfaces the red pilot lamp included in the STOP pushbutton lights up.

Owing to the fact that the reporting device of the forming apparatus, ofthe welding apparatus and of the separating apparatus are coordinatedtogether, the operator can define the type of problem that has occurredby reading the error message on the screen 125 that is nearest theoperator without moving from one end to the other of the productionline.

If necessary, the operator can then go to the apparatus in which themalfunction occurred and adopt the measures necessary for solving theproblem. When the problem has been solved, the corresponding errormessage disappears entirely from all three screens 125. At this point,the operator, from any of the three user interfaces UI1, UI2 or UI3, cansimultaneously reset all three apparatuses by pressing the RESETpushbutton. Subsequently the operator can simultaneously start up theentire production line by pressing the START pushbutton on any of thethree user interfaces UI1, UI2 or UI3.

From what has been shown above, it is obvious that the formingapparatus, the welding apparatus and the separating apparatus enablegreat flexibility because they are able to work both in isolation and tointerface between themselves to be integrated into a common productionline.

The invention claimed is:
 1. Apparatus for producing containers,comprising (a) a coupling device configured to couple a portion of aclosing film in the form of a continuous web with a sheet materialhaving a plurality of containing cavities, said coupling deviceincluding a lower plate interacting with an upper plate, (b) a cuttingunit for removing a portion of said closing film to define a zone ofsaid sheet material which remains uncovered by said closing film whensaid closing film is coupled with said sheet material, (c) a supplydevice supplying said closing film in a supply direction through saidcutting unit, and (d) an adjusting device for regulating the position ofsaid cutting unit along said supply direction, said adjusting deviceincluding a locking device for locking said cutting unit in a desiredposition along said supply direction.
 2. Apparatus according to claim 1,wherein said cutting unit comprises a shearing member for removing saidportion of said closing film by shearing.
 3. Apparatus according toclaim 1, wherein said cutting unit is positioned upstream of saidcoupling device.
 4. Apparatus according to claim 1, wherein saidadjusting device comprises a guiding element along which a supportingbase of said cutting unit is slidable, said guiding element extendingalong said supply direction.
 5. Apparatus according to claim 4, whereinsaid adjusting device comprises a driving device for moving saidsupporting base along said guiding element.
 6. Apparatus according toclaim 1, wherein said coupling device is included in a welding unit forwelding said closing film to said sheet material.
 7. Apparatus accordingto claim 1, and further comprising a joining device arranged upstream ofsaid coupling device to join a removing element to said closing film,said removing element being usable by a consumer for removing contentsfrom a containing cavity.
 8. Apparatus according to claim 7, whereinsaid joining device comprises a welding device for welding said removingelement to said closing film.
 9. Apparatus according to claim 8, whereinsaid welding device comprises a thermowelding device.
 10. Apparatusaccording to claim 8, wherein said welding device comprises anultrasound-welding device.
 11. Apparatus according to claim 7, whereinsaid removing element comprises a spoon element.
 12. Apparatus accordingto claim 7, and further comprising a positioning device to position saidremoving element on said closing film.
 13. Apparatus according to claim8, and further comprising a separating unit positioned downstream ofsaid coupling device for separating one or more containing cavities fromsaid sheet material.
 14. Apparatus according to claim 8, and furthercomprising a forming unit positioned upstream of said coupling devicefor forming said containing cavities on said sheet material. 15.Apparatus according to claim 14, and further comprising a filling unitinterposed between said forming unit and said coupling device forfilling said containing cavities with a desired product.
 16. A methodfor producing containers, comprising the steps of (a) supplying aclosing film in the form of a continuous web in a supply directionthrough a cutting unit, (b) removing a portion of said closing film insaid cutting unit, (c) coupling said closing film with a sheet materialhaving a plurality of containing cavities in a coupling device includinga lower plate interacting with an upper plate, (d) adjusting theposition of said cutting unit to adjust the position of the removedportion of the closing film, whereby after said coupling step, a presetzone of said sheet material faces a region of said closing film fromwhich said portion has been removed, and (e) immobilizing said cuttingunit in a desired position along said supply direction after saidadjusting step.
 17. A method according to claim 16, wherein said cuttingunit comprises a shearing member that removes said portion from saidclosing film by shearing.
 18. A method according to claim 16, whereinthe preset zone of said sheet material that remains uncovered by saidclosing film comprises a tab for opening a container including acontaining cavity.
 19. Method according to claim 16, wherein the presetzone of said sheet material that remains uncovered by said closing filmcomprises a protrusion that projects from a surface of said sheetmaterial opposite a further surface of said sheet material from whichsaid containing cavities project.
 20. A method according to claim 16,wherein said closing film is coupled with said sheet material bywelding.
 21. A method according to claim 16, and further comprising thestep of joining a removing element to said closing film before saidclosing film is coupled with said sheet material, said removing elementbeing usable for removing contents from a containing cavity of acontainer.
 22. A method according to claim 21, wherein said removingelement comprises a spoon element.
 23. A method according to claim 22,wherein said spoon element is substantially flat.
 24. A method accordingto claim 21, wherein said removing element is made of plastics material.25. A method according to claim 21, wherein said removing element isjoined to said closing film by welding.
 26. A method according to claim25, wherein said removing element is joined to said closing film bythermowelding.
 27. A method according to claim 25, wherein said removingelement is joined to said closing film by ultrasound welding.
 28. Amethod according to claim 16, and further comprising the step ofseparating one or more containing cavities closed by said closing filmfrom said sheet material after said closing film has been coupled withsaid sheet material.
 29. A method according to any claim 16, whereinsaid sheet material is shaped as a continuous strip.
 30. A methodaccording to claim 16, wherein said containing cavities are joined by astrip of said sheet material to form a discrete group of containingcavities.
 31. Apparatus according to claim 1, wherein removal of theremoved portions define openings within the closing film and whereinsaid adjusting device defines the openings in desired positions withinthe closing film corresponding with preset zones of the sheet materialthat remain uncovered by said closing film when the closing film iscoupled with the sheet material.
 32. A method according to claim 16,wherein removal of the removed portions define openings within theclosing film in desired positions of said closing film corresponding topreset zones of said sheet material, wherein the preset zones of thesheet material are positioned at said openings of said closing filmafter said coupling step.